US4605309A - Mixing and shearing roller-mill - Google Patents

Mixing and shearing roller-mill Download PDF

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Publication number
US4605309A
US4605309A US06/690,052 US69005285A US4605309A US 4605309 A US4605309 A US 4605309A US 69005285 A US69005285 A US 69005285A US 4605309 A US4605309 A US 4605309A
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roll
rolls
mill
roller
grooves
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English (en)
Inventor
August Albers
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COLOR METAL DR-ING ALBERS MASCHINENBAU Firma GmbH
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Hermann Berstorff Maschinenbau GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
    • B29B7/52—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices with rollers or the like, e.g. calenders
    • B29B7/56—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices with rollers or the like, e.g. calenders with co-operating rollers, e.g. with repeated action, i.e. the material leaving a set of rollers being reconducted to the same set or being conducted to a next set
    • B29B7/562—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices with rollers or the like, e.g. calenders with co-operating rollers, e.g. with repeated action, i.e. the material leaving a set of rollers being reconducted to the same set or being conducted to a next set with means for axially moving the material on the rollers
    • B29B7/564—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices with rollers or the like, e.g. calenders with co-operating rollers, e.g. with repeated action, i.e. the material leaving a set of rollers being reconducted to the same set or being conducted to a next set with means for axially moving the material on the rollers at least one of the rollers being provided with helicoidal grooves or ridges, e.g. followed by axial extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
    • B29C48/387—Plasticisers, homogenisers or feeders comprising two or more stages using a screw extruder and a gear pump
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/465—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using rollers

Definitions

  • the present invention relates to a roller-mill for continuously conveying, mixing, homogenising and plasticising rubber, plastics and other plasticisable materials in the shearing nip between two tempered rollers.
  • the present invention seeks to provide a device by means of which the material may be fed into the device in a controllable, reliable and uniform manner and which also permits the feeding of awkwardly-shaped and rough pieces of material into the roll nip.
  • the invention also seeks to provide a device by means of which a very brief overall dwell time for the material is achieved with a controllable advancing degree of plasticisation whilst the material is being axially conveyed in an advantageous manner.
  • a mixing and shearing roller-mill for plasticisable material comprising first and second rotatable, tempered rolls, each said roll defining a longitudinal axis, said rotation being effected about said longitudinal axis, drive means for each said roll for rotating said rolls at different speeds relative to one another, each said roll having an axial length and a diameter, said axial length being at least four times greater than said diameter, each said roll including an external surface, said external surface defining grooved portions, the transition regions between said surface and each said groove being sharp-edged, each said groove being inclinedly disposed at an acute angle relative to said roll axis, said grooves on said first roll having an opposite hand to said grooves on said second roll, each said roll defining first and second axial end regions and a central region intermediate said end regions, said material feed means disposed in said first end region and material discharge means disposed in said second end region, the number and depth of said grooves increasing from said first end region to said central region and decreasing from said central region to said second end region
  • the material located in front of the roll nip is subjected to a saw-like action and is chopped into pieces in the manner of two helical, counter-rotating roller-mills.
  • the material is thus forcibly pulled into the roll nip, irrespective of any incidental adhesion between roll surface and the material.
  • the central layer of the material undergoes very intensive, biaxial shearing.
  • the different surface speeds of the roll between which the material is trapped whilst located in the grooves of the two rolls necessarily cause different portions of the material to shear against one another in the nip, such shearing simultaneously being both radial and axial.
  • the layer thickness of the material located therebetween may, for example, be 1 mm. If, however, a smooth segment of one roll faces a groove on the other roll having a depth of, for example, 1.5 mm, the layer of material will have a thickness of 1 mm plus 1.5 mm, that is to say 2.5 mm, in one localised region. Obviously, if two grooves face one another, a layer thickness of material of 1.5 mm plus 1 mm plus 1.5 mm, that is to say 4 mm, is produced.
  • the grooves were from 0.5 mm to 10 mm deep, preferably from 1 mm to 5 mm deep, and were from 1 mm to 50 mm wide, preferably 1 mm to 10 mm wide.
  • the grooves preferably extend angularly relative to the axis of roll.
  • the groove bases are, desirably, semi-circular or rectangular with rounded edges in shape. Whilst a person skilled in the art would normally expect the material to adhere to, or sinter in, the base of the groove, exactly the opposite occurs utilising a roller surface which is grooved in accordance with the present invention.
  • the groove base is, effectively, rinsed clean by strong material vortices.
  • a gas, usually air, cushion accumulates in the base of the groove. As the rolls rotate and the roll nip is constantly increasing and decreasing in size, effective degassing occurs and causes the formation of the air cushion.
  • This air cushion slightly lifts rolled material which has been forced in the groove from the base of the groove base. This expands during operation of the roller-mill with an audible click.
  • the material is reliably fed into the roll nip. Even if non-homogeneous material is fed into the roll nip, large volumes of such material are simultaneously mixed in the nip, even at relatively high temperatures, so that the material is neither burned nor clinkered onto the roll surfaces.
  • cold fresh material or powder is supplied to the roller-mill in those regions of the mill where an intense shearing heat is produced.
  • Such cold material or powder being surrounded by semi-plastic material and is gently decomposed very rapidly.
  • any excess shearing heat produced is profitably used for plasticising the fresh material.
  • the overall energy consumption per kilogram of plasticised material is therefore extremely low and the roller-mill according to the present invention can be used for treating numerous different types of material having greatly differing viscosities.
  • a further requirement for achieving the object of the invention is the control of the axial flow of material so that the plastic material has a very brief, but uniform, dwell time in the region of the roll nip so that both its own properties and the roll surface in the immediate vicinity thereof are not adversely affected.
  • the grooves formed in the roll surfaces have opposite inclinations or pitches.
  • the angle which the grooves subtend with the axis of the rolls is between 1° to 45°, preferably 5° to 35°.
  • the most advantageous angle depends on a number of factors.
  • it depends upon the roll diameter, the basic roll nip, the spacing between the grooves and the difference in the speed of rotation of the two rolls.
  • a groove spacing of from 10 mm to 50 mm and an angle of inclination of from 7° to 30° provide good results both for the axial conveyance of material and for the axial shearing.
  • roll diameters of from 400 mm to 650 mm successful operations have been carried out using angles of inclination of from 5° to 25° and with groove spacings of from 6 mm to 25 mm.
  • a desirable facet of the invention provides that the number of grooves, that is to say, the inter-groove spacing and their depth are not identical over the entire axial length of the rolls. This is dependent upon the desired material flow rate and the viscosity of the material.
  • the feed end of the roller-mill may have a relatively small number of relatively shallow grooves so as to lengthen the dwell time of the relatively cold material.
  • the mixing and degassing effect produced is increased by using deeper grooves and twice or three times the number of grooves. This prevents shearing burning.
  • fine decomposition is achieved because the material is now semi-plastic.
  • Such decomposition is controlled by using fewer, shallower grooves.
  • the interior of the rolls are, preferably, heatable and coolable.
  • a temperature is initially set for the two rollers, the basic roll nip is selected and then the friction set up between the two rolls is adjusted by adjusting the rotational speeds of the rolls.
  • strips of material which have been partially plasticised to a desired extent can be removed from the mill by suitably selecting the location of the discharge point along the roll axis.
  • the plasticising process is freely accessible from externally.
  • impact resistant modifiers, fillers, dyestuffs, cross-linking components, foaming agents or even reinforcing fibres can be fed into the mill at pre-determined axial locations so as to ensure that they are only added when material is in a desired plasticised state.
  • a defined dwell period is selected by adding the material at a pre-determined location along the roll nip.
  • Axially adjustable feeding devices may be used for this purpose.
  • roller-mills such as moderate costs, reliable operation, robustness, little wear damage, easy cleaning during colour or dye change and universal utilisation also apply to the device according to the present invention.
  • devices for forcibly feeding the shearing nip are disposed at the feed end of the shearing roller-mill.
  • a speed-regulated geared pump is provided, by means of which the substance is pressed into the grooves in the rolls and thus fed into the homogenising process.
  • very tough to highly-viscous materials for example rubber spheres, are pressed against the sharp-edges of the grooves in the shearing roller-mill by means of sprocket chain advancing means, toothed roll advancing means or by means of a feed chute provided with a piston ram.
  • FIG. 1A is a graph which shows how the shearing factor occurring in the mill varies along the length of the mill;
  • FIG. 1B is a plan view of two rolls forming part of a roller-mill according to the present invention.
  • FIG. 2 shows, schematically, how four feed locations for different materials can be disposed along the length of the roller-mill shown in FIG. 1;
  • FIG. 3 is a plan view of a roller-mill in accordance with the present invention.
  • FIG. 4A is a longitudinal sectional view of an alternative embodiment in which a speed-regulated geared pump is disposed above the roller-mill at the feed end of the mill;
  • FIG. 4B is a cross-sectional view of the embodiment of FIG. 4A;
  • FIG. 5A is a longitudinal sectional view of a pair of toothed wheels disposed beneath the discharge end of a roller-mill;
  • FIG. 5B is a cross-sectional view showing the toothed wheels of FIG. 5A;
  • FIG. 6 shows the arrangement of a bearing housing above the feed end of a roller-mill according to the present invention
  • FIG. 7a is a schematic view of an internal shearing nip
  • FIG. 7b shows a shearing nip configuration formed between a shearing roll having a profile and a housing wall
  • FIG. 8 shows a conically tapering arrangement for the rolls, the mounting and nip adjustment being provided by a conically tapering casing or cover member for the barrel;
  • FIG. 9 shows a further embodiment, in which only one of the rolls is axially extended and is in the form of a discharging and extruding screw.
  • FIG. 3 One embodiment of a continuous mixing and shearing roller-mill in accordance with the present invention is schematically shown in FIG. 3.
  • the mill comprises two rolls 31, 32 which each have a diameter of 150 mm and a barrel length of 750 mm.
  • One roll 31 is driven by a motor 33 in a first direction and the other roll 32 is driven in the opposite direction by a second motor 34.
  • the rotational speeds of the two rolls 31 and 32 are adjustable independently of one another but both speeds generally lie in the range of from 5 r.p.m. to 50 r.p.m.
  • each roll is provided with a helically extending groove profile or configuration 35 and 36 respectively. These profiles 35 and 36 each subtend an angle of substantially 10° with the longitudinal axis of the roll on which it is formed.
  • the grooves in the two rolls 31 and 32 extend in opposite directions to one another.
  • Each groove is of varying depth and, in use, the material to be treated is caused to enter the mill at a first axial end region and is discharged from the other axial end region.
  • the groove depth is 0.75 mm. This increases to a depth of 2.5 mm in the central region of the roll and diminishes to 0.5 mm in the discharge end region.
  • the groove width is constant at 3 mm, this value having been selected for ease of manufacture.
  • the spacing between adjacent grooves is at a minimum.
  • This central region extends over 40% of the barrel length.
  • thirty-six grooves are distributed over the periphery of each roll in the central region.
  • This central region extends towards each axial end of the roll for a distance of 150 mm so that the axial length of the central region is 300 mm.
  • Adjacent this central region, and extending towards each axial end region, is a further region having an axial length of 125 mm.
  • Such region has eighteen grooves distributed over the periphery of the roll with a spacing of 26 mm between the grooves.
  • one roll was internally tempered with fluid at 180° C. and the other roll was internally tempered with fluid at 160° C. through supply members 37 which are mounted on the axis of the rolls but do not rotate therewith.
  • component A is an acetate-containing PVC-copolymer which has a relatively low melting point.
  • component B is a high-molecular weight PVC powder, component C is a filler material possibly including pigments and component D is an impact-resistant material or a glass fibre pulp.
  • component D is an impact-resistant material or a glass fibre pulp.
  • Such a roller-mill in accordance with the present invention is suitable for plasticising hard PVC and it is possible to obtain an output which is two- to three-times that obtained using a conventional roller-mill. It is obviously advantageous to be able to supply the individual components successively to the roller-mill because this permits the obtention of material combinations which improve the properties of the end product. Thus, for example, it is possible to ensure that there is a controlled inhomogeneity in the fine structure of the material. In the case of impact-resistant components, full shearing decomposition, which is the most feared disadvantage when using known devices, is reliably prevented. Moreover, powdered rubber compositions can be homogenised and masticated in one operation.
  • the rolls which rotate in opposite directions to one another are provided with groove profiles which are of opposite pitches to one another.
  • one roll has a right-hand thread or pitch and the other roll has a left-hand thread or pitch.
  • the shape or configuration of the groove profile is seleted in dependence upon the properties of the material to be mixed and/or plasticised.
  • a speed-regulated geared pump is provided, as is shown in FIGS. 5A and 5B.
  • the substance or material is pressed into the grooves in the rolls by means of the pump and can then be homogenised.
  • the grooves in the shearing rolls are made sharp-edged.
  • the material is then pressed against the sharp edges of the grooves by sprocket chain or toothed roll advancing means or by a feed chute together having a pressure ram incorporated therein.
  • shearing rolls may also be used, if desired, to combine and extrude processed material.
  • the construction of the device of the present invention for extruding the material depends on the nature and viscosity of the material.
  • the material is not removed using a conventional scraper. Instead, a pair of toothed wheels 21 forming part of a geared pump are utilised which wheels are located in the discharge region of the rolls. In such an arrangement, the grooved profile of the rolls are not inclined in the discharge region, as can be seen in FIG. 4a.
  • the toothed wheels may be connected to the rolls or may be driven and controlled independently of one another.
  • the material is received between the teeth of the wheels and is conducted, for subsequent pressure extrusion, to a mouthpiece or nozzle provided at the pressure and discharge end of the geared pump 22.
  • This arrangement which is shown in FIGS. 5a and 5b, is particularly advantageous if very viscous, stickly materials are being treated.
  • the provision of separate drive means for the toothed wheels means that the extrusion and discharge device is a separate entity which can be easily attached to and removed from the roller-mill and can therefore be readily replaced. It does not, therefore, interfere with the actual roll system.
  • shearing rolls define an open shearing nip at the feed end of the device, this being due to the provision of two conventional, bearing housings 71 shown in FIG. 6.
  • the shearing rolls are, however, continuously profiled with grooves at their discharge end and are mounted in a bearing housing 72, 73 in the manner similar to that a twin-screw barrel extruder.
  • the barrel casing has a conically inwardly tapering discharge aperture formed therein.
  • This casing is axially slipped over substantially the discharge end of the rolls and covers the region in which the plasticising process is completed.
  • the casing causes rheological conditions to be produced in this region, which condition is similar to that existing in non-meshing, friction-driven twin-screw systems wherein the screws are driven in opposite directions.
  • the ends of the rolls are provided with continuous grooves which acts as screw threads.
  • the threads terminate in the housing in conically tapering tip portions.
  • the shearing nip between the two rolls increases in size in a direction toward, and as far as, the tapered tip portions.
  • the surface profile of the shearing rolls is completely different, the build-up of pressure in the plastic material and the support of the shearing nip pressure against the barrel walls are much more intensive. This is technically more advantageous than is the case in conventional, known twin-screw systems.
  • the advantages of the open shearing roll system for the processing method and the twin-screw principle for the shaping process are not lost.
  • FIG. 7a is a schematic view of the internal shearing nip 41 formed between the profile 42 of the two shearing rolls which are frictionally operated.
  • FIG. 7b shows the nip configuration 43 formed between a shearing roll having a profile 42 and the housing wall 44.
  • FIG. 8 also shows conically inwardly-tapering, grooved shearing rolls 51 and 52. At the material feed end, these rolls have a conventional, adjustable shearing nip 53 formed therebetween.
  • the mounting and the nip adjustment for the conically tapering rolls at the discharge end are provided by a suitably tapering cover or casing member 54 for the barrel.
  • this cover member 54 is axially displaced in one of the directions of arrow 55, the narrower nip being towards the feed end of the device and the larger shearing nip extending away from such end.
  • only one of the two shearing rolls has an axially extended portion.
  • Such roll in the form of a discharge and extrusion screw, is surrounded by a suitable barrel casing 62 of a single screw system which is advantageous in flow technology.
  • the other, counter-setting roll 63 includes a separate setting mechanism 64, as in the case of the embodiment shown in previous Figs, and also permits, therefore, the control of the rear shearing nip from externally.
  • the shearing roll system Even if there is an overflow of material in the shearing roll system, the excess material drops into a collecting tank and can be recycled from the tank without damage. Altogether, the system proves to be robust and operationally reliable.
  • the described additional devices for the feeding process permit the shearing roll system to be intrinsically associated with the actual development course of the method.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Mixers With Rotating Receptacles And Mixers With Vibration Mechanisms (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US06/690,052 1984-01-16 1985-01-09 Mixing and shearing roller-mill Expired - Lifetime US4605309A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP84100370A EP0148966B2 (de) 1984-01-16 1984-01-16 Kontinuierliches Misch- und Scherwalzwerk
EP84100370.0 1984-01-16

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US4605309A true US4605309A (en) 1986-08-12

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US (1) US4605309A (xx)
EP (1) EP0148966B2 (xx)
JP (1) JPS60202723A (xx)
AT (1) ATE31506T1 (xx)
DE (1) DE3468192D1 (xx)

Cited By (12)

* Cited by examiner, † Cited by third party
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US4773762A (en) * 1986-02-06 1988-09-27 August Albers Continuous mixing and shearing rolling mill
US4963296A (en) * 1986-10-16 1990-10-16 Wnc-Nitrochemie Gmbh Process for the preparation of propellant charge powder
DE4012294C1 (xx) * 1989-05-11 1991-02-14 Wnc-Nitrochemie Gmbh, 8261 Aschau, De
US5005982A (en) * 1989-06-21 1991-04-09 Kistner Kenneth J Material processor
US5137368A (en) * 1989-06-21 1992-08-11 Specified Equipment Systems Co., Inc. Viscous fluid pumping apparatus and system
DE19528052A1 (de) * 1994-07-29 1996-02-01 Poudres & Explosifs Ste Nale Kontinuierliches Verfahren zur lösungsmittelfreien Herstellung von pyrotechnischen Composit-Produkten
US5505591A (en) * 1993-07-30 1996-04-09 Tynan; Daniel G. Apparatus for processing materials
US6197104B1 (en) 1998-05-04 2001-03-06 Millennium Inorganic Chemicals, Inc. Very high solids TiO2 slurries
US20040217221A1 (en) * 2001-08-31 2004-11-04 August Albers Rolling mill system
CN103980071A (zh) * 2014-05-06 2014-08-13 西安近代化学研究所 一种用于炸药捏合碾片的滚筒装置
US20150360399A1 (en) * 2013-01-14 2015-12-17 Cabot Corporation Method and apparatus for processing elastomer composite
US20160040355A1 (en) * 2013-03-15 2016-02-11 Patrik Björnvall Bin arrangement for the collecting and discharging of smaller ligno-cellulosic material

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Publication number Priority date Publication date Assignee Title
SE465572B (sv) * 1989-06-21 1991-09-30 Nobel Kemi Ab Saett och anordning foer framstaellning av explosiva substanser
SE501223C2 (sv) * 1992-08-28 1994-12-12 Bofors Explosives Ab Sätt och anordning för att framställa pyrotekniska satser genom valsning
DE9214486U1 (de) * 1992-10-27 1992-12-10 Color Metal Dr.-Ing. Albers Maschinenbau GmbH, 7843 Heitersheim Misch- und Scherwalzwerk für plastifizierbares Material
DE4300298C2 (de) * 1993-01-08 1994-12-15 Degussa Verfahren zur Herstellung von mit Hartstoff- und/oder Metallpulvern versetzten flexiblen Kunststoffbändern
DE4334697A1 (de) * 1993-10-12 1995-04-13 Condux Maschinenbau Gmbh & Co Kontinuierliches Misch- und Scherwalzwerk
JP4887673B2 (ja) * 2005-07-04 2012-02-29 横浜ゴム株式会社 ゴム組成物の混練方法及び混練設備

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US4047705A (en) * 1974-09-28 1977-09-13 Krauss-Maffei Aktiengesellschaft Extruder with dual tapered screws
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US827936A (en) * 1905-10-27 1906-08-07 Carl F Obermaier Rubber warming and mixing mill.
US4047705A (en) * 1974-09-28 1977-09-13 Krauss-Maffei Aktiengesellschaft Extruder with dual tapered screws
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Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4773762A (en) * 1986-02-06 1988-09-27 August Albers Continuous mixing and shearing rolling mill
US4963296A (en) * 1986-10-16 1990-10-16 Wnc-Nitrochemie Gmbh Process for the preparation of propellant charge powder
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Also Published As

Publication number Publication date
EP0148966B2 (de) 1991-01-16
JPH0347131B2 (xx) 1991-07-18
DE3468192D1 (en) 1988-02-04
EP0148966A1 (de) 1985-07-24
ATE31506T1 (de) 1988-01-15
JPS60202723A (ja) 1985-10-14
EP0148966B1 (de) 1987-12-23

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